Sarreguemines/Haiger - The AKG Group relies on high-tech automation from CLOOS to weld aluminium components at its French site in Sarreguemines. The specialists for heat exchangers and cooling systems use two CLOOS robot systems and numerous manual welding machines in their production. "With the two robot systems, we have significantly increased our productivity," explains Sacha Jung, Managing Director of AKG France. "By using the welding fume extraction torch and the laser sensor on the new robot system, we have been able to realise considerable energy savings and improved working conditions."
The AKG Group has been developing and producing high-performance heat exchangers and complete cooling modules and systems for construction machinery, compressed air systems, industrial coolers, agricultural and forestry machinery, vehicle construction, rail vehicles, aviation, municipal vehicles, household appliances and special applications for more than 100 years. More than 3,500 employees produce over 2.5 million heat exchangers in various designs every year. In addition to the French site, there are 10 other independent production sites and 14 sales companies around the world. As a leading global provider of customised system solutions, the AKG Group is committed to the highest quality standards. This is why AKG relies on automated welding solutions from CLOOS.
High-tech robot system increases productivity
The company commissioned the first robot system at its French production site back in 2015. Last year, another robot system with high-tech automation components followed. The centrepiece of the system is the QIROX QRC-350-E robot. The long reach of the 7-axis robot simplifies and speeds up the welding of complex workpieces. The C-shaped stand positions the robot overhead on a fixed arm. This position of the robot enables better accessibility to the workpiece and simplifies the welding of larger workpieces.
The C-frame is mounted on a floor track that moves the robot in a horizontal direction. The new robot system consists of two stations that can be used flexibly for different components. The two-station principle of the robot system makes it easy to insert the components in one station while the robot is welding in the other station - an enormous time saving in the process sequence. "With the new robot system, we were able to significantly reduce cycle times compared to manual welding," says Alex Reiff, Head of Welding Production.
Torch-integrated fume extraction system
The new system is equipped with a torch-integrated fume extraction system. This provides safe and effective extraction of welding fumes directly at the source. Up to 95 per cent of the fumes are eliminated directly during the welding process at the point of origin near the arc. With the first robot system, AKG still had to invest in an elaborate extraction system with curtains, complex pipe systems and a large filter unit to extract and clean the contaminated air. With extraction directly at the welding torch, the volume of polluted air is now much smaller. By using the extraction welding torch system, AKG had to invest significantly less in extraction technology, air guidance system and filter unit - with the same effect. A flexible hose with a small diameter replaces the complex pipe system for conveying the contaminated air to the filter unit. The smaller volume of polluted air means that a smaller filter unit is required. A further advantage: the optimised energy efficiency and the minimised costs for cleaning and replacing the filter components significantly reduce operating costs. In addition, AKG was even able to significantly simplify and speed up the entire production process thanks to the burner-integrated fume extraction system. While the first system had to be laboriously loaded by hand, a crane solution can be used for loading and unloading in the new system due to the space saved.
This is particularly pleasing for the production staff. "For me, the biggest advantage of the new system is the direct extraction at the welding point," explains system operator Mickaël Thielges. "This means there is more space above to carry out the various transport tasks with the overhead crane." Last but not least, the employees benefit from the clean air and the better working environment thanks to the direct fume extraction.